Automatic Fuel Oil De-aerator Flow-Control

12 Pages·2008·0.37 MB·English

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Instruction Manual
Automatic Fuel Oil De-aerator
EN 12514-2
Flow-Control
Flow-Control 3/K-1 # 69942
Flow-Control 3/K-2 # 70019

(cid:14)
Read manual before use!
(cid:14)
Observe all safety information!
(cid:14)
Keep manual for future use!

07.2008 0
854.001.0351
Contents
1 About this instruction manual...................................................................................3
1.1 Structure of warning.....................................................................................3
1.2 Explanation of symbols and typeface...........................................................3
2 Safety.......................................................................................................................4
2.1 Intended use.................................................................................................4
2.2 Predictable incorrect application..................................................................4
2.3 Safe handling................................................................................................4
2.4 Qualification of personnel.............................................................................4
2.5 Modifications to the product..........................................................................5
2.6 Use of spare parts and accessories.............................................................5
2.7 Liability information.......................................................................................5
3 Product description..................................................................................................5
3.1 Function........................................................................................................6
3.2 Application examples....................................................................................7
4 Specifications...........................................................................................................8
4.1 Approvals, tests and conformities................................................................8
5 Installation and commissioning................................................................................8
5.1 Right dimension of the suction tube.............................................................9
5.2 Pressure test..............................................................................................10
5.3 Parallel connection.....................................................................................10
6 Troubleshooting.....................................................................................................11
7 Spare parts and accessories.................................................................................11
8 Warranty................................................................................................................12
9 Copyright................................................................................................................12
10 Customer satisfaction............................................................................................12
11 Addresses..............................................................................................................12

2 Flow-Control
About this instruction manual
1 About this instruction manual
This instruction manual is part of the product.
(cid:88) Read this manual before using the product.
(cid:88) Keep this manual during the entire service life of the product
and always have it readily available for reference.
(cid:88) Always hand this manual over to future owners or users of the
product.
1.1 Structure of warning

WARNING TERM The type and source of danger is shown here.
(cid:88) Precautions to take in order to avoid the danger are shown
here.

There are three different levels of warning:
Warning term Meaning
DANGER Imminent danger!
Failure to observe the information will result in
death or serious injuries.
WARNING Possible imminent danger!
Failure to observe the information may result in
death or serious injuries.
CAUTION Dangerous situation!
Failure to observe the information may result in
minor or serious injuries as well as damage to
property.

1.2 Explanation of symbols and typeface

Symbol Meaning
(cid:59) Prerequisite for an activity
(cid:88) Activity consisting of a single step
1. Activity consisting of several steps
(cid:170) Result of an activity
•
Bulleted list
Text Indication on a display
Highlighting Highlighting
Flow-Control 3
Safety
2 Safety
2.1 Intended use
The automatic fuel oil de-aerator Flow-Control may only be used in
single-line systems with return pipe connection for continuous de-
aeration of the following liquids in oil-fired systems:
Liquid Flow-Control 3/K-1 Flow-Control 3/K-2
Light fuel oil EL according to DIN 51603-1 X X
Diesel according to EN 590 X X
Fuel oil with 0-20 % fatty acid methyl ester X X
(FAME) according to EN 14213
Fuel oil with 0-100 % fatty acid methyl ester – X
(FAME) according to EN 14213

Any use other than the use explicitly stated in this instruction manual
is not permitted.
2.2 Predictable incorrect application
The automatic fuel oil de-aerator Flow-Control must never be used in
the following:
• Use with undissolved additives, alcohols and acids
2.3 Safe handling
The automatic fuel oil de-aerator Flow-Control represents state-of-
the-art technology and is manufactured in accordance with the perti-
nent safety regulations. Each unit is subjected to a function and
safety test prior to despatch.
(cid:88) Operate the automatic fuel oil de-aerator Flow-Control only
when it is in perfect condition. Always observe the instruction
manual, all pertinent local and national directives and guidelines
as well as health and safety regulations and directives regarding
the prevention of accidents.
2.4 Qualification of personnel
The product may only be installed, commissioned, operated, main-
tained, shut down and disposed of by qualified, specially trained per-
sonnel.
Law or building codes may require an inspection by local or federal
authorities.
4 Flow-Control
Product description
2.5 Modifications to the product
Changes or modifications made to the product by unauthorised per-
sons may lead to malfunctions and are prohibited for safety reasons.
2.6 Use of spare parts and accessories
Use of unsuitable spare parts and accessories may cause damage
to the product.
(cid:88) Use only the manufacturer’s genuine spare parts and accesso-
ries (refer to chapter 7, page 11).
2.7 Liability information
The manufacturer shall not be liable for any direct or consequential
damage resulting from failure to observe the technical instructions,
guidelines and recommendations.
The manufacturer and the sales company shall not be liable for costs
or damages incurred by the user or by third parties in the use or ap-
plication of this device, particularly in case of improper use of the de-
vice, misuse or malfunction of the connection, malfunction of the de-
vice or of connected devices. The manufacturer or the sales com-
pany shall not be liable for damages resulting from any use other
than the use explicitly stated in this instruction manual.
The manufacturer shall not be liable for misprints.
3 Product description

Fig. 1: Flow-Control 3/K-1 Fig. 2: Flow-Control 3/K-2
Flow-Control 3/K-1 consists of a diecast zinc housing with a con-
nection thread at the tank side and connection threads for connec-
Flow-Control 5
Product description
tion of the burner hoses. The float chamber is made of transparent
plastic.
Flow-Control 3/K-2 is equipped with two separate float chambers.
The first float chamber consists of a de-aerator hood with operating
and de-aerating float. The second one is a safety float chamber. It
prevents the oil foam from escaping via the de-aerator opening (e.g.
during commissioning/filter exchange) and indicates malfunctions of
the de-aerator valve. The float chambers are made of transparent
plastic.
3.1 Function
a Q = Q
Tank nozzle
b Q
Supply
c Q
Return
d Q
Nozzle

Fig. 3: Flow-Control 3/K-2 with filter
The burner pump draws the fuel oil from the tank via the filter and the
non-return valve installed in Flow-Control and delivers it to the noz-
zle. The excess oil (i.e. the oil exceeding the nozzle capacity) is
pumped into the float chamber via the return pipe. While the oil level
gradually increases in the float chamber, the oil is de-aerated by the
de-aeration valve.
When the oil reaches a level of approx. 1 3/16” above the bottom,
the floats begin to operate and actuate the bypass valve, thus deliv-
ering the de-aerated return oil to the suction pipe.
This way, the system only withdraws the amount of oil from the tank
via the filter which is actually needed for combustion. This consid-
erably prolongs the filter service life. The maximum possible service
life can be obtained with the long filter insert made of sintered plastic
(Optimum).
The oil that now flows to the pump primarily consists of de-aerated
fuel oil plus oil from the tank that still contains air.
6 Flow-Control
Product description
3.2 Application examples
a Max. 15 ft
Fig. 4: Installation of Flow-Control 3/K-2 above the tank level with
self-securing suction pipe (steady gradient to the tank). The non-
return valves in the withdrawal fitting or at the end of the suction
hose must be removed.

a Diaphragm
anti-siphon
valve
b Static pre-
pressure for
sizing the anti-
siphon valve
Fig. 5: Installation of Flow-Control below the tank level. It is recom-
mended to install a diaphragm anti-siphon valve or an oil safety valve
to prevent fuel oil from escaping in the case of a defective suction
line with a higher oil level in the tank.
In case of fire, the valve will prevent oil from running out and intensi-
fiying the fire.
Flow-Control 7
Specifications
4 Specifications
Table 1: Specifications
Parameter Value
General specifications
Dimensions: (W x H x D)
Flow-Control 3/K-1 3.74” x 5.90” x 3.74”
Flow-Control 3/K-2 3.74” x 7.87” x 3.74”
Burner connection ¼-NPZ inner thread
Tank connection ¼-NPZ inner thread
Nozzle capacity Max. 26 gph
Return flow Max. 37 gph
Oil flow Max. 58 gph
Separation capacity air/gas Up to 4 l/h
Mounting position Float housing vertical to the top
Operating overpressure Max. 10 psi
Suction vacuum Max. 7.5 psi
Test pressure Max. 85 psi
Operating temperature range
Ambient Max. 140 °F (60 °C)
Operation Max. 140 °F (60 °C)

4.1 Approvals, tests and conformities
Flow-Control is TÜV-tested, report no. V132 2007 V1.
5 Installation and commissioning
(cid:88) Install Flow-Control between the burner and the shut-off valve,
close to the oil burner.
(cid:88) Never use Flow-Control in ambient temperatures greater then
140 °F. Do not mount the product in the vicinity of uninsulated
burners, over burner opening flaps or next to chimney flues.
(cid:88) Mount the float chamber vertically, pointing to the top, so it fits
securely and cannot come loose..
(cid:88) Use oil hoses as per local codes for connection to the oil pump.
8 Flow-Control
Installation and commissioning
(cid:88) Ensure that the pump is set for two-pipe operation when mount-
ing the product. Bypass plug must be installed.
(cid:88) Install an oil filter in the supply line in order to protect Flow-
Control.
(cid:88) A 3/8" pipe is sufficient for most installations. In larger systems
requiring ½" pipes (if the consumption is less than 5 ¼ gph), all
parts of the pipes leading upwards should be calculated as suc-
tion height. If the suction pipes are larger than ½", this should
be taken into consideration as well (even if the consumption
amounts to more than 5 ¼ gph). Large pipes with low flow rates
may cause gas accumulations, resulting in insufficient suction in
the downward sections.
(cid:88) Mount Flow-Control as shown in fig. 3, page 6.
(cid:88) Remove all check valves between Flow-Control and tank.
(cid:88) Never install a shut-off valve or other device, which can impede
flow in the lines between the oil de-aerator and the oil pump.
(cid:88) All pipework must be tested during installation.
(cid:88) Never use Flow-Control with pump pressure between tank and
Flow-Control.
(cid:88) Test the completed installation for correct function and fire secu-
rity before starting.
(cid:88) Only one fuel unit per Flow-Control connection.

CAUTION Damage to the pump or Flow-Control due to incorrect connec-
tion of supply and return connections.

(cid:88) Do not confuse the supply and return connections (not even
during commissioning for a short period of time).

5.1 Right dimension of the suction tube
Tabelle 2: Standard values for tube dimensioning
Volume flow in the suction tube Tubing size copper
0-13 gph 5/16”
8-24 gph 3/8”
18-37 gph ½”

Flow-Control 9
Installation and commissioning
5.2 Pressure test
When subjecting the suction pipe to a pressure test, the pressure
connection must not be made at the Flow-Control unit since the non-
return valve integrated in the device does not allow the pressure to
be applied to the suction pipe. Therefore, the device is not to be in-
cluded in the pressure test.
5.3 Parallel connection
The built-in check valve permits connection of several oil burners to
the same feed line. In this case, the total oil consumption must be
used when calculating this pipe resistance. For larger capacities, two
or more Flow-Control can be connected in parallel.
a Return
b Supply
c Tank
Fig. 6: Parallel operation of two Flow-Control 3/K-2 units
10 Flow-Control